Stapler



Nov. 7, 1961 Original Filed April lO, 1956 HAzEL 3,007,172

STAPLER Nov. 7, 1961 Original Filed April lO, 1956 H. K. HAZEL Nov. 7, 1961 STAPLER 9 Sheets-Sheet 3 Original Filed April l0, 1956 Nov. 7, 1961 H. K. HAzEL 3,007,172

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l W M W M United States Patent O 3,007,172 STAPLER Herbert K. Hazel, Arlington, Va., assignor to Melpar Inc., Alexandria, Va., a corporation of New York Original application Apr. 10, 1956, Ser. No. 577,329, now Patent No. 2,947,4'47, dated Aug. 2, 1960. Divided and this application Apr. 25, 1960, Ser. No. 36,104 12 Claims. (Cl. 1-323) This application is a continuation-in-part of Hazel, Serial No. 577,329, tiled April 10, 1956, for Component Feed and Insertion, now Patent No. 2,947,447, August 2, 1960.

This application is related in subject matter, to applications for United States patent, as follows:

Lawson et al., Serial No. 413,092 filed March l, 1954 for Stapling Machines, now Patent No. 2,904,785, September 22, 1959.

Lawson et al., Serial No. 413,072 filed March 1, 1954 for Modular Circuitry, now abandoned.

Vosson et al., Serial No. 492,392 tiled March 10, 1955 for Stapling Machines, now Patent No. 2,904,786, September 22, 1959.

Vosson et al., Serial No, 473,251 led December 6, 1954 for AutomaticMachinery, now Patent No. 2,868,- 413, January 13, 1959.

Hazel, Serial No. 413,782 tiled June 7, 1955 for Stapling Machines, now Patent No. 2,778,691, January 22, 1957.

This application is also related to the following applications for United VStates patent, filed concurrently Vwith the parent application, as follows:

K. Hazel & B. Vosson for Automation, Serial No. 577,330, now Patent No. 2,911,646. t

B. Vosson for Wafer Feed and Insertion, Serial No. 577,328.

The present invention relates generally to automatic machines for fabricating electronic sub-assemblies, and more particularly to automatic or semi-automatic machines for assembling electrical components, such as resistors, selected automatically from a large number of available'types, at pre-selected positions on a wafer, and soldering the components to printed circuitry previously placed on the wafer.

The problem of automatic assembly or fabrication of electrical or electronic sub-assemblies is receiving considerable attention, and various approaches have been attempted. In `accordance with the present invention, a wafer, in the form of a thin sheet of insulating material, is provided with a plurality of aperture pairs, for insertion of the terminal leads of standard electrical components therein.

Each wafer is provided with pre-tinned printed circuitry on one of its sides, and the components are secured to the other side, the Wire terminals of the components passing through the apertures, being bent into stapled relation to the wafer and into intimate Contact with the printed circuitry. During the stapling process the wire terminals are heated sufficiently to form a soldered joint with the printed circuitry. By pre-tinning the printed circuitry, just the correct thickness of solder may be made available, and no problems of solder application arise in the operation of the machine.

Once a selected component has been made available to the stapling position, and a wafer has been appropriately positioned, a stapling and soldering head is'actuated pneumatically. The stapling head removes a component from stapling position, bends the wire leads of the component at right angles to the component, carries the component down to the wafer, and inserts the bent leads through the apertures in the wafer. The anvil of the stapling and soldering head moves up under the tion to provide a novel automatic machine for fabricating electronic or electrical sub-assemblies.

It is a further object of the present invention to provide a novel device for forming an electrical component as a staple, and for inserting the staple in a wafer.

A further object of the invention resides in the provision of a component stapling unit, wherein the component may be stapled to the Wafer at selectively different spacing with respect to the wafer, to make allowance for different thicknesses of component body.

lThe above andV still further objects, features and advantages of the present invention will become apparent upon consideration of the following detailed description of one specic embodiment thereof, especially when taken in conjunction with the accompanying drawings, wherein:

FIGURE 1 is a View in front elevation of a staple forming and stapling head;

4FiGURE 2 is a view corresponding with FIGURE 1, illustrating a different position of certain parts;

FIGURE 3 illustrates in section actuating and adjusting elements for the forming and stapling head of FIG- URES l and 2;

FIGURE 4 illustrates in section detail elements of the forming and stapling head;

FIGURES 5 to 8 illustrate various positions of a stapling and inserting head in the course of forming and inserting an electrical component into a Wafer;

FIGURES 9-12 taken together constitute a circuit diagram of a system in accordance with the invention.

Forming and staplng Components 101 are delivered one by one to the .delivery end of channel (FIG. 4). As each component is delivered it is stapled to the wafer apertures then available and properly positioned. Each component reaches the delivery end of channel 130 with considerable velocity. The inertial energy of the component causes the latter to pass over forming jaws 150, 151, illustrated 0n FIGURE 1. In the process the `advanced end of the component drops, while the rearward position is still supported by the conveyor. The forward lead eventually impinges on a cam surface CS, which raises the forward lead in response to the inertia of the component, and levels the component. The component is substantially level when it passes completely from the conveyor, causing same to drop liat in the process of sliding ot cam CS and onto the forming jaws 150, 151. The latter, for the purpose of receiving the component, come together in a V, an apex 154 of which is formed in one of the jaws, 151, only. Accordingly, the component 101 is supported in one of the jaws, 151, the other jaw serving to guide the coponent to the apex 154, and to assist in mechanically supporting the jaw 151. The apex 154 lies below the level of the base 131 of V-shaped channel 13,0, and the end wall of the latter, together with stop 152, serve to center the component longitudinally, with considerable accuracy, with respect to the staple forming and inserting mechanism.

The two jaws 150, 151 are rigidly held together. The jaw 151 is pivoted on a pin 155, while the jaw 150 is pivoted on a similar pin 156. A lever arm 157 is secured to jaw 151, extending toward pin 156l and terminating in a pin 158. A similar lever arm 159 is secured to jaw 150 and extends toward pin 155, terminating in an end slot 160. The end slot 160 engages the pin 158.

Accordingly, the jaws 150 and 151 are constrained to pivot in synchronism and together on the pins 155, 156, respectively, and neither can move without the other.

The jaw 151 is normally locked. To this end, a pin 162 is provided on jaw 151, and a camming slot 163, in a camming plate 164, engages the pin 162. The camming plate 164 is pivotably secured on a stationary pin 165 secured to a convenient portion of the frame of the machine.

'.[he camming plate 165 supports, inwardly of jaw 151, a cam roller 167, and is spring biased into the position illustrated in FIGURE 1 by a spring 168. Sufiicient downward pressure on a cam roller 167 will therefore swing the plate 165 counterclockwise, while release of such pressure will permit return of the plate 164.

The cam slot 163 contains essentially two differently directed slot elements. One element, 170, extends arcuately at an angle of substantially 80, or slightly less than 90, to ther'horizontal, the arc centered on the axis of pin 165. The remaining element 171 extends at an angle of substantially 30 to the horizontal, and may be linear. The pin 162 normally rests within the element 170, below the knee 172 formed in member 164 by the junction of slot elements 170, 171, and is horizontally aligned with pin 165. The parts described are so oriented and proportioned that downward pressure applied at apex 154 of jaw 151, tending to rotate jaw 151 to open position, forces pin 162 against one side of slot element 170, on a line with the axis of pin 165. The applied force is thus transmitted through plate 164 to pin 165, which is rigid, and is located in alignment with the force. Accordingly, no downward motion of point 154, consequent on counter-clockwise rotation of jaw 151, is possible for this orientation of plate 164.

When, however, downward force is applied to cam roller 167, the member 164 pivots suiiiciently to enable pin 162 to ride over knee 172, and into slot element 171. That slot element is so oriented that pin 162 moves freely therein. No further restraining force is then exerted by plate 164 on pin 162. In fact downward pressure applied to cam roller 167 tends to move pin 162 along slot 171. I aw 151 now swings freely, forcing jaw 150 into a complementary motion. The jaws then separate rapidly (FIGURE 2). On release of cam roller 167 the spring 168 brings member 164 up, relocking the jaws 150, 151.

In forming and stapling a component, the operations required are:

(l) to clamp the component leads against the forming jaw 151,

(2) to bend the leads over the forming jaw, at right angles to their original directions,

(3) to remove the forming block,

(4) to carry the staple down to its wafer, and to insert the bent lead ends in apertures provided in the wafer,

(5) to position the component properly vertically with respect to the wafer,

(6) to hold the component steady while the lead ends protruding beyond the wafer are bent under and soldered.

Initially, the component leads 103 are supported on the notch 154, in jaw 151. The body 102 hangs freely in a recess 175 in the jaws. This body is fragile, and the leads 103 must therefore be subjected to no unnecessary bending or turning forces at any points thereof which are adjacent to the body.

The operation of holding the leads 103 firmly, preparatory to staple forming is performed by the holder head 176. The latter includes a pair of pressure elements, 177, separated by a recess 178 to provide clearance for body 102. The holder head 176 comes down with the forming lingers 179, and presses the leads 103 firmly against notch 154, to prevent any subsequent motion of the leads. The leads 103 are held at points adjacent the body 102 by pressure elements 177.

Thereafter, the forming fingers 179 continue to descend, while the holding head remains stationary, and

bend the ends of leads 103 about the vertical walls of jaw 151. The forming fingers 179 include a cam element 180, FIGURE l, which actuates the cam roller 167 to effect separation of the jaws 150, 151. Accordingly, when the forming process is complete the jaws 150, 151 separate, and the fingers 179, with the bent component leads held frictionally therebetween, descends past the open jaws 150, 151 (FIGURE 2) down to the wafer.

When the forming fingers 179 have reached a position in proximity -to wafer 10, the holder head 176 is forced downwardly with respect to lingers 179, sliding the component out from between the forming fingers 179, and forcing the formed ends into a pair of apertures 41, in wafer 10, which have been preliminarily suitably positioned to receive same. The downward motion of holder member 176 is automatically adjusted, at this time, in accordance with the thickness of the body 102, so that the latter will just lie at against the wafer, and will not be either compressed, and thereby damaged, nor be spaced from the wafer, and hence not adequately supported. The holder head then retains its final position until a heated anvil rises under the wafer, upsets the lead ends, and solders these to printed circuitry on the underside of the wafer.

The holding head 176 and forming fingers 179 are relai tively translatable, but both are also actuatable together by means of pneumatic motor AM-2 (See FIGURE 4). The latter includes a piston 182, movable in a cylinder 183, and positively actuatable upwardly in response to Ypneumatic pressure supplied via a conduit 184, or downwardly in response to pneumatic pressure applied via a conduit (FIG. 3). The piston 182 is secured immovably to an upwardly extending piston rod 186, and to a downwardly extending piston rod 187. Rods 186, 187 move through suitable sealing elements, 189 such as 0- rings, to maintain the pressure-wise integrity of cylinder 183. The forming fingers 179 are secured for movement with rod 187, as by means of a pin, or pins, 190.

A recess 191 is provided adjacent the lower end of rod 187, which provides a pneumatic cylinder for 'a piston 192, the latter having limited motion, and being normally biased upwardly by means of a helical spring 193. Extending downwardly from piston 192 is a rod 194 and extending upwardly is a rod 195, bothrods being secured to piston 192 and actuated thereby.

Y The rod 195 further passes freely through a thickness variable pneumatically controlled spacer motor AM-10, having a piston 201, vertically movable in a cylinder 202. The piston 201 is normally in its downward position, but may be raised by a predetermined amount in response to pneumatic pressure supplied via conduit 203. The actual difference in thickness between the bodies of two specific electrical components may be of the order of .047. In such case the total motion of piston 201 may be predetermined to equal this same amount.

The upper end of rod 195 may be provided with an adjustment nut 205, which is stopped in its downward travel by an upwardly extending boss, 206, secured to piston 201. The maximum downward travel of rod 195 may be adjusted by adjustment of nut 205, and selected to have either of two values according to the position of boss 206. The motor AM10 may be secured to a transverse beam 207.

A further beam 208 extends parallel to beam 207, and above it. A vertical rod 210 is vertically translatable with respect to and through a bearing 209 in beam 208, and is in alignment with rod 195. The rod 210 includes a stop nut 211 at its upper end, and a spring retaining flange 212 adjacent its lower end. A helical spring 213, extending between the under side of beam 208 and the flange 212, biases the rod 210 downwardly, with considerable force (about 40 pounds).

Operation of forming and staplng head Describing now the operation of the forming and stapling head, the structural features of which have been hereinabove described in detail, pneumatic pressure is applied to the underside of piston 182, and exhausted from the upper side, raising the latter. This condition is illustrated in FIGURES 3 and 4.

The bias spring 213 is compressed, forcing piston 192 to its lower position against the force exerted by bias spring 193.

When pneumatic pressure is applied to the upper wall of piston 182 and exhausted from the lower, the piston 182 moves downwardly. Due to the force exerted by spring 213 on flange 212, rod 210, impelled by spring 213, follows, and by way of rod 195, piston 192 and rod 194 retains the holding member 176 and the forming fingers in their relative positions, as illustrated.

The holding member 176 clamps a pair of component leads against forming notch 154, and is stopped. The pressure exerted by the holding member 1'76 is then that exerted by the spring 213, essentially.y

The forming fingers 179 continue downwardly, bending the ends of leads 103 at right angles, over the forming jaws 150, 151. When this operation is complete the forming jaws 150, 151 are cammed open, and the forming fingers 179, with the formed component retained therebetween frictionally, moves further.

At approximately the point in the cycle of operations at which forming begins the upper end of rod 195 disengages from rod 210, so that lthe holding member 176 may withdraw and does not force the component between the forming fingers 179. The latter are carried down to a position adjacent the wafer, previously positioned to accept the component. At this point in the motion of piston rod 186 the channel 198 moves within cylinder 183, and consequently supplies pneumatic pressure to pistonv 192. The latter moves downwardly, forcing the component leads from between the forming lingers 179, and into engagement with the wafer. However, the maximum possible downward motion of the rod 195 is established by the stop 206, so that the extent to which the leads of the component are forced through the wafer apertures, and consequently the final position of the component body, is similarly thus determined.

The holder 176 retains its -iinal position until the component leads are upset by a heated anvil ASH, which moves up under the wafer, bends the protruding lead ends under, and heats them sufficiently that they are soldered to the pretinned printed circuitry on the under side of the wafer.

Description of control circuitry and brief description of overall system operation The reference numeral 300 identifies a source of A.-C. voltage, one side of which is connected with a relay coil K-l directly, and the other side of which proceeds to the relay coil K-1 via a push-button switch S-2. When the switch S-2 is closed, the relay K-1 is energized, operating the step switch K1a. Alternate energization of coil K-l alternately opens and closes the contacts of switch Kla. When closed the lines 302, 303 are supplied with A.C. power. The lines 302, 303 are connected to a rectifier unit CR-l, and continue beyond, to supply A.C. power to various instrumentalities of the system. The terminals 306, 307 of the rectifier CR-l provide D.C. power, respectively vof positive and negative polarity.

Component feed and insertion In the presently described embodiment of the invention, provision is made for the selection of any of six electrical components, stored in six different hoppers Obviously, any desired number may be provided for. Selection of a desired component is accomplished by energizing a selected component hopper, each energization of a selected hopper resulting in delivery of the component type `stored by that hopper, to a station at which thecomponentis automatically stapled and soldered to a pre-wired and pre-tinned wafer. Component selection is accomplished by selective manual interlocked switches S-6 the several selection switches being identified by the letters A-F, inclusive. The position G of switches S-6 is retained to control wafer transfer, and the switch interlock feature assures that selection of any component, `or initiation of wafer transfer', can take place selectively only, and one at a time, in that closure of any pair of contacts of switches S-6 is accompanied by opening of any contacts theretofore closed.

Preparatory to component selection, a condenser C-7 (FIG. l2) is charged from the D.C. line. The charging circuit extends from negative line 307, via line 308, and via switch S-1-O, the now closed K-5 switch contacts, and back to positive line 306. When one of switches S-d-A to S-6G is closed, it locks, unlocking any previously activated one of these switches. Assume switch S-6-A to be the selected switch. A circuit is then completed via line 310, via that one of component feed solenoids which is responsive to switch S-6-A, and to the movable arm 311 of a two position switch 312, having stationary contacts 313, 314. The terminal 313 is connected to a line 315, and the terminal 314 to a line 316, so that either line 315 or line 316 is selected by twoposition switch 312. The alternate positions of the latter are selected (by means of mechanism hereinbefore described) in accordance with the character of the hopper which stores the component involved, i.e. in one specific example of the system, in accordance with whether a 1A Watt, or a 1/2 watt resistor hopper is associated with switch S-6-A. The relays 115 serve to actuate the component feed gates of the system, each of which releases a single component, in response to an electrical impulse applied thereto by discharge of condenser C-7.

The line 316 is connected to one terminal of an unlatching coil 317, and the line 315 to one terminal of a latching coil 318 of a latching, two-position relay 319. The remaining terminals of coils 317, 318 are connected together and to line 307, which is the negative D.C. line. Accordingly, the position of switch 312, which selects one of lines 315, 316, determines the position of armature 321 of latching relay 319, and therefore whether a line 322 Vwill be connected to a power line 302, or not. The condition of line 322, i.e. energized or not, controls an adjustment of a stapling head of the system, so that it may effectively staple the type of cornponent delivered, keeping in mind that the bodies of electrical components of different sizes are of different diameters, and that it is desired to staple each component into the same precise proximity with a wafer, so that allowance must be made for component diameter in establishing proper operation of the stapling head.

Having selected switch S-6-A, the switch S-li is manually closed. This action connects power line 302 to a lead 323, which supplies power to coil K-5-A, throwing the associated switch armature 321 to the contact 325, and completing a circuit from the positive side of condenser C-7, through contact 325, and back via line 326 to line 310. The condenser C-7 then discharges through coil 115, which causes the appropriate component to drop from its hopper for delivery to stapling head, and also through the appropriate one of relay coils 317, 318 which, by activating armature 321 to one of its two possible positions, conditions the stapling head for the size of component involved.

It will be clear that selection of any one of switches S-6A-S6F will in a manner similar to that above described, result in dropping of a component from the corresponding hopper and in |adjustment of the stapling head, so that it may effectively staple components of the particular size stored in the selected hopper.

The selected component drops on the air slide AS, which immediately and automatically conveys the component to a stapling station. At the latter is located a photo-cell PC and a light source LS. The latter normally maintains the forms illuminated. The cathode of the photo-cell PC are connected via lead 330 to the cathode side of a tetrode gas tube or thyratron GT. The anode of the photo-cell PC is connected via lead 331 to the control grid of the tube GT. The A.C. lines 302, 303 are connected, via leads 332, 333, to the primary side of a transformer T-2. One terminal of the secondary side is connected to the heating filament of gaseous tetrode GT via lines 334. The secondary winding of transformer T-Z is connected to the primary winding of a further transformer T-l, the secondary winding of which is connected at one terminal to the cathode of tetrode GT via a voltage dropping resistance 335, and at the remaining terminal via switch contacts 336, and via relay coil K-401 to the anode of the gaseous tetrode GT. From the contacts 336 a lead 337 proceeds to dropping resist-ance 338, and thence via voltage divider resistance 339 to the cathode of tetrode GT. The control electrode of tetrode GT is connected via lead 340 to the variable tap of resistance 339, via resistance 341. The photocell PC is then connected at its anode directly to the control grid of tetrode GT, and at its cathode directly to the low potential terminal of resistance 335. The cathode of tetrode GT is, when its anode is positive, above the potential of the cathode of photo-cell PC, by virtue of the voltage drop across resistance 335. The photo-cell PC, when illuminated and conductive, introduces a voltage drop at resistance 333, which reduces the A.C. control grid voltage below that of the cathode of tetrode GT. The tetrode GT is thus maintained non-conductive, even while its anode is positive, When photo-cell PC is unilluminated, and hence non-conductive, the A.C. potential on the control grid of tetrode GT is not depressed, and the tetrode GT becomes conductive during positive half cycles of Voltage applied to its anode.

So long as the photo-cell remains illuminated the tube GT remains non-conductive, then, and the relay K-401 unenergized. When the selected component arrives at its position -at the component forming and insertion head, or stapling head, as it is lsometimes denoted herein, the photo-cell illumination ceases, the tetrode GT becomes conductive, and relay K-401 is energized. Its contact then pulls up, applying A.C. power from line 302 to lead 350, and then to the normally closed contacts of switch S302, and thence on lead 350a to solenoid controlled pneumatic valve Al-304 and back to line 303. The normally withdrawn insertion head motor AM-Z is now actuated downwardly.

While the insertion head IH is in its uppermost position, a cam 354, located on the piston rod thereof, maintains a switch 304 in open condition. After the head travels downwardly a short distance, the switch S-304 closes, preparing a circuit for normally open switch S-303. When the head IH h-as traveled downwardly through its entire stroke and completed its staple forming and insertion function, the cam 354 closes switch S-303 completing a circuit for solenoid controlled pneumatic valve Al-302. The circuit for the latter proceeds from line 303, via leads 355', switch S-304, switch S-303, and back to lead 302.

Operation of solenoid operated valve .AK-302 provides pneumatic pressure to pneumatic motor AM-3 which actuates the anvil and soldering head ASH upwardly. A heating circuit for the latter is provided directly between leads 302 and 303, 356 being the heating coil. As the yanvil and soldering heat ASH starts to move upward, it breaks a circuit at switch S-301 from the lead 302.

When the anvil and soldering head ASH has completed its travel, at which point it impinges against a stop, pressure on the under chamber of pneumatic motor AM-3 builds up suciently to actuate pressure responsive switch S-302. The latter completes a circuit from lead 350 to lead 356 breaking the circuit to lead 350d. The latter operation breaks the circuit to solenoid operated valve Al-304, causing the insertion head 1H to rise by introducing air pressure to the underside of motor AM2. As the latter rises to its uppermost position cam 354 opens cam switch S303, which breaks the circuit between line 302 and line 355, via switch S-304, which in turn deenergizes solenoid activated valve AK-302, and causes the motor AM-Z to withdraw the anvil soldering head ASH. When the insertion head IH has risen,I photo-cell PC becomes illuminated again, the tetrode GT becomes non-conductive, relay K-401 becomes de-energized, and its switch is thrown to break the circuit between leads 302 and 350, and to make a circuit between lead 302 and pilot light DS-2.

The conditions of pilot lights DS-l and DS-2 signals to the operator when an operation is in process, and when it has been completed. Only after completion may the closed one of switches S-6 be actuated to select a further component.

The process of bending over the lead ends 103 in the course of a stapling operation, requires that the component be held with considerable force against upward movement. This force is provided by the holding member 176 (FIGURES 5 8), which is at this point in the cycle of operations pneumatically impelled downwardly, but p0- sitioned in its farthest point of travel by stop 206 (FIGURE 3). The anvil ASH also moves against a stop, or has a limit of travel, at which staple forming is complete. Thereafter, pneumatic pressure builds up further in the under side of the cylinder of anvil motor AM-3, luntil sufficient pneumatic pressure exists to operate pressure switch S-302. This process introduces a predetermined time lag. Operation of switch S-302 controls insertion head motor Alvi-2, which rises. The anvil, ASH, remains however in its uppermost position until the insertion head has completely risen, throwing switches S-304 and S-303 to their original or unactivated positions, and exposing the photo-cell PC to light source from LS. Opening of switch S304 permits the anvil to retract. During the period of rise of the insertion head IH the sole back pressure on the anvil is that provided by its stop, and it is during this period of rise that soldering is completed. The time of rise may be adjusted to provide proper dwell time for the soldering head ASH, and thus controls soldering time. Thereafter, i.e. when photo-cell is again illuminated, the anvil ASH retracts. Complete retraction of anvil ASH is signaled by re-closure of switch S-301, which closes a circuit from line 302, to relays K-7 and K-4-A. The relay K-7 pulls over, and completes a circuit for relay K-8, which breaks the circuit to relay coil K-4-A. Relay coil K4A is an unlatching coil, for armature 406, and the function of relays K-7, K-8 is, therefore, to pulse relay K-4-A, or to ass-ure that it will be de-energized shortly after it has been energized, thus preventing oscillation, or repeated operation.

A reset pulse for relay K-S is provided on closure of switch S-3-A, which is momentarily actuated in response to actuation of any of wafer selection switches S-3. Reset operation of relay K-S, by resetting armature 321, closes the charging circuit for condenser C-7, preparatory to a further component selection. This sequence provides a protective interlock for preventing more than a single component feed for any wafer position selection.

Wafer position selection For each selection of a component, as by actuation of a selected one of switches S6A to F, inclusive, it is necessary to select a wafer position, which is accomplished by selection of one of switches S-3-1 to 14, inclusive. The possible wafer positions are arranged in two longitudinally extending parallel lines, having seven positions, in each line, the lines displaced laterally from each other. The wafer selection switches are correspondingly placed, and are interconnected in pairs. The upper ones of switches S-3-1 to S3-7, inclusive, select the seven longitudinal positions. Each lower switch includes one contact 400, which parallels the contacts of the corresponding upper switch;

9 and an additional contact 401, which signals that a lateral displacement of the wafer is required.

Consider now the upper row of switches S-S-l to S-3-7, inclusive, and particularly the switch S-3-1. The latter, at one contact is connected with wafer positioning solenoid controlled pneumatic valve Al-201, over lead 402, and thence to power lead 3&3. The remaining switch contact is connected to a common lead 405, to open contact of relay K-fi. Relay coil K-4 is connected in parallel with relay coil K-Sa, so that on closure of manual switch S-4 relay coil K-4 and K-Sa are energized, armature 406 completing a circuit between line 392 and dos. Operation of valve Al-210i causes the piston of positioning `servo AM-l to assume a position corresponding to the selected valve Al-201. The lateral shift valve AM-S is not operated at this time, since completion of its circuit depends on completion of a circuit from lend 404 through solenoid 4h97 of valve Al-26d, and via lead 408, which connects with A.C. line 303, and via the contacts 4M of switch S-3, back to lead 465, which connects with A.-C. line 362, through the contacts of relay K-i. Hence valve AK-Zt operates only if one of switches S-S-S to S-S-M is peratcd.

The shift motor AM-S is spring biased to its unactuated position, so that only while one of switches S-S-S to S45-14 is closed is the shift motor actuated.

Lock motor (pneumatic) Alvi-i is normally energized and its locking plunger rod is accordingly normally pressed downwardly by air pressure controlled by solenoid controlled pneumatic valve Al-209. The circuit for the solenoid of valve Al-209 may be traced from power lead 303, back through lead alb, normally closed switch S-Ztll and back to line 362. When air is exhausted from any of the exhaust lines EL deriving from the pneumatic servomotor .AM-1, the switch S-Zill is opened by the pressure of the exhaust gases. The lock solenoid is then de-energized, removing air from lock motor Alvi-4 and per` mitting the pin 71 to rise in response to force exerted by spring 69. Once a positioning operation has been completed, exhaust of gases ceases because the previously opened exhaust line EL is closed by the piston of motor AM-ll. The switch S-Zl then closes again, and the locking pin moves downwardly to lock the wafer positioning carriage 35.

By selecting dilferent ones of the switches S-3-1 to S3-7, inclusive, or S-3-8 to S-S-i, inclusive, different ones of the positioning valves AK-Zl to Al-207 are activated, but in each case the operation is the same. lf, however, one of switches S-3-S to S3-l4, inclusive, is operated, the additional operation takes place that lateral shift motor AM-S is actuated, shifting the wafer carriage laterally.

Wafer transfer The name Wafer Transfer is given to the oper-ation which transfers a wafer from the wafer chain conveyor to the wafer positioning carriage. Wafer transfer is signaled by the switch S-6-G. Actuation of this switch throws all of component selection switches S-6A to FV to unactuated position, the switch S-6 being mechanically arranged to permit only one of its sets of contacts to be actuated at any one time. Switches of this character are :available on the open market and therefore need not be described or illustrated in detail. The movable element of the switch S-6-G is connected via 450 and normally closed contacts of lock-switch K-4, K-4A to power lead 302. Switch S-6-G serves to connect lead 451 to lead 450, which proceeds to relay coil K-6, and to power lead 303. The armatures of switches K-6-1 to K-'5-4 are moved to the left, and locked when relay coil K- is energized. VThe now active contact of switch K-6-2 is connected via lead 452, through S-308, which is closed in only the #l position of the carriage. Hence, so long as the wafer positioning carriage is not in position #1, so that switch S-SGS is open, the wafer transition circuit is open and wafer transition is prevented.

The #1 position of the carriage is the one position assumed by the carriage which wafer transfer is possible, and devices are provided, which are hereinafter described, to effect return of the carriage to #l position whenever Wafer transfer is requested by actuation of switch S--G.

Further, in order to permit transfer of a wafer from the chain conveyor into its carriage, the wafer carriage must be brought to the standard position. The standard position is that which obtains when switch S-S-l is selected. Accordingly, lead 452; is extended to switch K-6-3 so that the latter and S-3-1 are in parallel, and when switch K-6-3 is actuated the carriage moves to the standard position.

The chain advance motor is AM-S, which is controlled by solenoid responsive valves Al-3% and Al-307, the latter, Iwhen activated causing the motor AM-S to retract, and the former causing the motor AM- to advance. Initially, the motor AM-S is in retracted position, as illustrated. The wafer transfer motor AM-7 is, on the contrary, normally in advanced position, i.e. in the position it assumes to insert a wafer in the carriage and from which it may abstract an assembled wafer. When switch S--G is closed, then, the required sequence of operations is:

(l) Retraction of transfer motor Alvi-7, which abstracts an assembled wafer from the wafer carriage and deposits same on the chain for ultimate movement to an unloading point;

(2) Chain feed by motor AM-S, to an extent suiicient to place a succeeding wafer in position before the carriage;

(3) Advance of motor AM-7 to transfer the succeeding wafer from the chain into the carriage.

Insertion of a iirst component is accompanied by return of the chain advance motor AM-'7 into ready position `for a further advance.

Switch contacts K-6-2, when closed by coil K-, connect a lead 46), via normally closed contacts of a switch S-311, to the solenoid of valve Al-305. The solenoid of valve Al-36S is at this time in de-energized state, and its valve consequently in exhaust position. The wafer transfer motor AM-7 accordingly retracts, removing `a wafer from the carriage and depositing same on the chain conveyor. Normally closed switch S-Slt is opened, responsive to the initial movemen-t of motor AM-7.Y Switch S-3l2 is closed when the motor AM-7 completes its travel. This closure signals completion of removal of a wafer from the positioning carriage, and of deposit of an assembled wafer on the chain. A power circuit is now completed, by switch S-3li2 'between leads 460 and 303, for the solenoid of valve Al-306. The chain advance motor AM-S is actuated, in response, a suicient distance to provide a new Wafer at loading position. In the course of travel of the piston of chain advance motor AM-3 to load a wafer on the carriage the following events occur in sequence:

(l) Switch S-309 is closed;

(2) Switch S-309a is closed; and

(3) Switch S-Sll is loperated to open one of its sets of contacts and close the other.

One contact of switch S-309 now proceeds to a now open circuit, at switch K-6-4. Switch S-309a provides a direct connection between lead 303 and lead 460 for solenoid Al-306, by-passing switch S-312, and at the end of the stroke switch S-Stl is actuated, which closes the previously open circuit to valve Al-368, and opens the previously `closed circuit to valve Al-305. The wafer transfer motor AM-l1 now feeds forward transferring a now wafer to the wafer positioning carriage. As the` motor AM-7 advances it .opens the switch S-312, at the beginning of its advance, and closes the switch ifi-310 at the end of its advance. Switch S-310, when closed, energizes pilot light DS-ll. The wafer transition motor AM-7 remains in its advanced position, therel 1 1 Y Y after, until the wafer is completely assembled and is required to be removed. It will be recalled that the jaws of the wafer transition open automatically, after they have advanced suicient-ly to deposit a wafer in its holder, thus permitting wafer-carriage positioning without interference from the wafer transfer devices.V

The process of component insertion and of wafer positioning may now be proceeded with; in accordance with the description hereinabove provided. On depression of the first one of component selection switches S-6-A to F, inclusive, the transfer switch S-6-G is actuated to its original position, which deenergizes coil K-6 and energizes coil K-6A. Contacts K-G-fl are actuated thereby, which energizes valve Al-306, through switch S-309, now closed, and de-energizes valve AK306, retracting the chain advance motor AM-S. The precise degree of motion required is imparted to the chain by a pawl, actuated by the motor AM-S to drive a link of the chain directly, and which impinges on a stop -to terminate the chain driving stroke. When the motor AM-S has completed its return stroke, the switch S-309 opens, removing power from solenoid Al-397.

Lead thickness compensation The problem which arises in connection with the stapling of components of different sizes has been described hereinbefore. To recapitulate briefly, the insertion head is required to clamp, bend and insert the components, for certain variations of body thickness. It has been found that variations of body thickness do not noticeably affect the operation of the system, except in respect to insertion. Since the components are secured by their leads, and moved in response to force applied to the leads, in the insertion mechanism, if all components were moved toward the wafers until their leads were the same height above the wafers it would follow that if the thinner bodied Vcomponents were positioned precisely in contact with the wafers, the thicker bodied components would be crushed, while if the thicker bodied components were properly placed, the thinner bodied ones would not be in suicient proximity to the wafers. For this reason it is necessary to adjust the insertion mechanism for the size of components being inserted. The lowermost point to which the holding member 176 of the insertion head may move is determined by the location of a stop 205 on the piston rod 195 of the insertion head, i.e. pneumatic pressure drives the holding member 176 toward the wafer until the piston rod is stopped (see FIGURE 3). The stop is made adjustable, in accordance with the present invention, by utilizing the two-position pneumatic motor .AM-10 as the stopping element. The motor is controlled by a solenoid activated pneumatic valve AIC-303. The solenoid of valve AK-303 is controlled by the positions of the switch arm 321, hereinabove described, i.e. in one position of switch arm 321 power is transferred from lead 302, to lead 322, to energize solenoid operated valve Al-303. In the alternate position the switch is open and power is not transferred.

A series of switches S-1-A to W is employed in order to transfer control of the system from the manual switches S-6, S-3 and S-4 to a punched card reading device which automatically supplies signals to the system. It will be noted in this respect that each lead which is connected to the contacts of the several manually controlled switches is also connected to punched card reader device PCR, for which may be substituted any desired remote control unit capable of supplying electrical control signals in required sequence to the control leads.

A preferred form of punched card reading device employable to control the operation of a system in accordance with the present invention is described and illustrated in an application for U. S. patent filed in the name of Bernd Vosson, entitled Card Reader, Serial No. 627,- 036 filed December 7, 1956 and assigned to the assignee of the present application. Nevertheless, any device capable of providing the required electrical signals to the system may be employed in the system, and more speciically the device employed need not be a punched card read-out device, but may supply programming signals derived from magnetic tape, punched tape, manually operated switches, or any equivalent device known in the art.

While I have described and illlustrated one specific embodiment of the present invention, it will become apparent that variations of the specific details of construction may be resorted to without departing from the true spirit and scope of the invention as dened in the appended claims.

The claimed subject matter is as follows:

l. A system for stapling an electrical component to a wafer by its own leads, said component having a relatively fragile body and a pair of oppositely extending collinear leads, comprising a stapling head, an anvil positioned under said stapling head, means for securing said wafer at a position intermediate said stapling head and said anvil, said stapling head including means for securing and supporting said electrical component, said stapling head also including means for bending the ends of said leads at right angles to said body, means for actuating said component securing and supporting means for translating said component toward said wafer to affect insertion of the bent ends of said leads through said wafer, means for activating said anvil into upsetting relation to said leads, said securing and supporting means and said bending means being positioned for securing said leads only against motion responsive to said anvil and arranged to apply substantially no strain to said relatively fragile body.

2. A system for stapling an electrical component to a wafer by means of its own leads, said component having a body and a pair of oppositely extending collinear leads, comprising a stapling head, said stapling head including a pair of separable jaws, means for supporting said jaws in relatively pivotable relation, means for pressing inner portions of said leads against said jaws, means for bending the outer portions of said leads at right angles to said body against said jaws as formers, means for pivotably separating said jaws, said bending means including means for carrying said component between the separated jaws to said wafer.

`3. A system for stapling an electrical component to an apertured wafer by its own leads, said component having a body and a pair of oppositely extending collinear leads, comprising a stapling head positioned over said wafer, an anvil positioned under said wafer, means for supporting said electrical component intermediate said stapling head and said wafer, said stapling head including forming elements for bending ends of said leads at right angles to said body to form a component staple, said bending means including means for transferring said staple component to a position adjacent said Wafer, means for abstracting said component staple from said forming elements and inserting the bent component leads through apertures in said wafer, said last means including means for automatically controlling the position of said component vertically with respect to said Wafer in accordance with the size of said component.

4. A system for stapling to a support either of two components, a rst of said components having a relatively fragile body of one thickness, a second of said components having a relatively fragile body of another thickness, including a stapler element actuatable toward said support to a stapling position and means for controlling the spatial relationship between said wafer and said stapling position selectively in response to an electrical control signal.

5. A system for stapling, comprising a translatable staple forming and inserting device, means for activating said staple forming and inserting device to deliver a staple to one of a plurality of predetermined spatial positions, an adjustable device comprising a'uid pressure responsive element having a chamber of one thickness when subjected to fluid pressure, and of another thickness when not subjected to fluid pressure, and means for controlling said spatial positions selectively in response to the thickness of the chamber of said fluid pressure responsive element.

6. A staple forming and inseiting device comprising a staple forming device, said staple forming device including a pair of separable staple support elements, means for maintaining said staple support elements in normally conjoint physical relation, -comprising a locking device, and means for unlocking said locking device to permit separation of said separable staple support elements.

7. A staple forming device comprising a pair of separable staple supporting jaws, means biasing said jaws toward conjoint relation, a pivot for each of said jaws, linkage means for enforcing conjoint synchronized motion of said jaws labout said pivots, a cam having a camming slot, a cam follower secured rigidly to one of said jaws, said cam follower movable in said camming slot and having a normal position in said camming slot, said camming slot arranged Ito lock said cam follower against motion in response to forces tending to separate said jaws while said cam follower is in said normal position, and means for unlocking said cam follower comprising means for moving said cam from the normal position thereof.

8. A staple forming device comprising a pair of normally conjoint but separable staple supports, said staple supports when conjoint forming a V-shaped receptacle for a rectilinear staple blank, the base of said receptacle being slightly displaced yfrom the boundary between said supports, means for automatically feeding staple blanks to said receptacle in alignment, means for bending elements of said staple blanks over said supports to form staples, said last means comprising a staple forming head movable toward said V-shaped receptacle, means normally locking said staple supports in conjoint relation, and means responsive to predetermined movement of said staple forming head during a staple forming operation to unlock said staple supports and by continued movement to separate said staple supports, thereby to release the formed staple.

9. A staple forming and inserting mechanism for a staple which includes a relatively fragile body secured between two co-axial wire leads, comprising a pair of separable jaws which when in conjoint positions provide a V- shaped receptacle, the staple being supported by said wire leads only substantially in the apex of said V-shaped receptacle, a staple forming and inserting head having holding fingers and staple forming ngers, said holding fingers arranged to hold a relatively small inward portion of each of said wire leads firmly against said apex, when actuated in a first direction to a first position relative to said staple forming fingers, forming fingers arranged when actuated to bend the remaining outward portion of each of said leads at right angles to their original directions, a first pneumatic motor for actuating said forming fingers, a first piston in said first motor, Ia first piston rod secured to said piston, means securing said forming linger-s to said rst piston rod, a further pneumatic motor, said further pneumatic motor having a further piston and a further piston rod actuated by said further piston, means securing said holding fingers to said further piston rod, a relatively Weak bias means normally urging said fuitther piston in a second direction which is opposite to said first direction, relatively strong actuating means for actuating said further rod in said first direction Ithrough a stroke adequate to attain said first position only, means for energizing said first pneumatic motor to actuate said staple ,forming fingers, and means for energizing said second pneumatic motor in response to predetermined movement of said first piston rod, to move said holding fingers to a position slightly beyond said first position relative to said staple forming fingers.

10. The combination in accordance with claim 9 wherein is provided means for controlling selectively the total stroke of said second pneumatic motor.

ll. In combination, a pair of normally conjoint pivotable jaws, a pivot element for each of said jaws, means constraining said jaws to move in opposite directions simultaneously, means for 'locking at least one of said jaws against motion, a translatable member having a cam thereon, cam means for activating said cam and means responsive to actuation of said cam means by said cam on said translatable member for unlocking said at least one of said jaws against motion and for actuating said jaws into non-conjoint relation.

12. In combination, a first pneumatic motor comprising a first pneumatic cylinder, piston and piston rod, a second motor including a second pneumatic cylinder, piston and pisto-n rod, said second pneumatic motor located internally of said first piston rod, means for pneumatically energizing said first motor, and means responsive to predetermined movement of said first piston when said first motor is energized for pneumatically connecting said first and second cylinders, whereby to activate said second pneumatic motor.

References Cited in the file of this patent UNITED STATES PATENTS 

